Weil-McLain CGI-4E manual Item 8

Page 56

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

11c Troubleshooting — control module lights (cont.)

CHART 6 — FLAME light flashing and POWER light on steady

ALSO — Troubleshooting failure to establish main flame

Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

• Are main manual shutoff valve and boiler gas valve open?

 

 

 

 

 

 

•

Is pilot flame visible through inspection port?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

TURN OFF POWER to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Check the voltage across

 

• Make sure ground wire

• Open main manual shutoff valve and boiler gas valve (per

 

 

 

 

 

 

 

 

 

 

 

 

 

 

terminals PV and C of the

 

 

terminal is securely fastened

 

Operating instructions in this manual).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

gas valve.

 

 

 

 

 

 

 

 

to control module mounting

• Turn on power at service switch or breaker. A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is 24 VAC present there?

 

 

screw.

 

 

 

 

 

 

 

Does FLAME light flash now?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Boiler should be in

 

•

 

Verify inlet gas pressure at gas

 

 

 

 

 

 

•

If the wiring from the

 

 

• Check the voltage across

 

 

 

valve:

 

 

 

 

 

 

 

 

 

 

 

 

 

control module to gas

 

 

 

terminals MV and C of the

 

normal operating

 

 

 

Natural gas — 5.0" w.c. min/14.0"

 

 

 

 

 

 

valve is intact, replace the

 

 

 

gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

sequence.

 

 

 

w.c. max

 

 

 

 

 

 

 

control module.

 

 

 

 

Is 24 VAC present there?

•

Observe operation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Propane — 11.0" w.c. min/14.0"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

Yes

 

until thermostat is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

w.c. max

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

satisfied and blower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is gas present at gas valve inlet and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

has completed its

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

post-purge cycle.

 

 

 

 

 

within above range?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Verify inlet gas pressure at gas valve:

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Natural gas — 5.0" w.c. min/14.0" w.c. max

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Propane — 11.0" w.c. min/14.0" w.c. max

 

 

•

TURN OFF POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to boiler at service switch or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is gas present at gas valve inlet and within above range?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

breaker.

 

 

 

• Contact gas supplier to correct

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Remove burner shield (see

 

 

 

pressure or gas supply.

 

 

 

 

 

No

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 40, item 4, page 60

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

for location).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

TURN OFF POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to boiler at service switch or

 

 

 

•

TURN OFF POWER to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Check flame signal — Detach sense lead from ignition control

• Verify pilot gas line is not

 

 

 

 

breaker.

 

 

 

 

kinked, obstructed or

 

 

 

• Remove burner shield (see

 

 

 

 

(Figure 38, item 8, page 50).

 

 

 

 

 

 

 

 

damaged and is correctly

 

 

 

 

Figure 40, item 4, page 60 for

 

 

 

•

Connect negative lead of MICROAMMETER to control sense

 

attached to pilot and gas

 

 

 

 

location).

 

 

 

 

terminal (Figure 38, item 8, page 50). Connect positive lead of

 

valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MICROAMMETER to sense wire.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Verify pilot ignition electrode,

 

 

• Verify pilot burner is securely

 

 

 

•

DISCONNECT red wire connected to terminal MV of the gas

 

electrode ceramic and spark

 

 

 

attached to pilot bracket, bracket

 

 

 

 

valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lead wire from control are in

 

 

 

 

is securely attached to cross tie,

 

 

 

•

Turn on power to boiler and allow to cycle. As soon as pilot is

 

good condition. Spark gap

 

 

 

 

and there is no corrosion on the

 

 

 

 

burning, the MICROAMMETER should read at least 1.0

 

should be approximately 1/8".

 

 

parts which would affect the

 

 

 

 

microamp.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Correct any above problems,

 

 

 

ground path for flame sense.

 

 

 

 

 

Is flame signal at least 1.0 microamp?

 

 

 

replacing pilot if burner or

 

 

 

• Verify that pilot flame rod, flame

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wiring is damaged.

 

 

 

 

rod ceramic and lead wire from

 

 

 

 

 

No

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Reinstall burner shield to

 

 

 

 

control module to flame rod are in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operate boiler for retest after

 

 

 

good condition.

 

 

 

•

If none of the previous steps

 

• If the wiring from the

 

any changes or corrections.

 

 

 

• Correct any above problems,

 

 

 

 

(including replacing pilot)

 

 

 

 

 

 

 

 

 

 

control module to gas

• If none of the above corrects

 

 

 

replacing pilot if burner or wiring

 

 

 

 

corrects problem, then replace

 

 

 

 

 

 

 

 

 

valve is intact, replace the

 

problem, then replace the

 

 

 

 

is damaged.

 

 

 

 

the control module, reinstall

 

 

 

 

 

 

 

 

 

 

 

control module and retest.

 

control module and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

burner shield and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

56

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part Number 550-110-711/1108

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 55 Page 57
Image 56
Page 55 Page 57
Contents GOLDCGi-4E How it works Gold CGi-4EGas-Fired Induced-Draft Water Boiler Contents Please read before proceeding 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following Check for nearby connection to1b Prepare boiler location clearances Chimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system 1d Prepare boiler location air contamination Remove contaminants permanentlyProducts to avoid Areas likely to have contaminants1e Prepare boiler location air openings Air openings must be providedAir opening options Two openings Air supply from inside the buildingExhaust fans and air movers Motorized air dampersSingle air opening option Exception for large spaces2a Prepare boiler placement & setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners2b Prepare boiler pressure test Hydrostatic pressure testDrain and remove fittings Prepare boiler for test3a Venting general information Venting chimney draft ventingCGi-4E venting methods Chimney draft or Direct exhaust Chimney draft venting3c Venting Direct exhaust components Obtain vent system componentsDo not exceed data in Table Do not mix components3d Venting direct exhaust vent starter 3e Venting direct exhaust termination Do not wrap or insulate vent pipe or fittings3f Venting direct exhaust installation Slip connector for Saf-T VentDo not mix types or manufacturers of vent materi- als Use their specified sealant. Do not use screwsUsing any termination other than one of those shown 4a Water piping general information Closed-type expansion tank 4b Water piping single-zone systemDiaphragm-type or bladder- type expansion tank Figure 4c Water piping multiple zones Piping multiple zonesBoiler isolation balancing valves System or zone circulator Zone valve Drain valve4d Piping low temperature systems Temperature gaugesValve adjustment Primary/secondary preferred bypass piping methodBlend temperature gauge Valve adjustment BOILER-bypass piping methodBoiler-bypass piping Zoning with SYSTEM-bypass piping method 4e Water piping refrigeration system Prevent chilled water from entering boilerSystem or zone circulator Chilled medium from entering boiler. See forConnecting gas supply piping to boiler Gas pipingNatural Gas Propane GasField wiring Electrical installation must comply withWiring connections ThermostatFreeze protection when used 7a Start-up preparationCheck for gas leaks Determine if water treatment is neededFill the system with water Inspect system water pipingInspect base insulation Close manual and automatic air vents and boiler drain cockCheck system and boiler 7b Start-up operate boilerStart the boiler Main burner flame Figure Check burner flamesPilot burner flame Figure High limit switch set below boiler water tempera- ture? 7c Start-up if boiler doesn’t startCheck for Gas not turned on at meter or boiler?Check-out procedure checklist 9a Operation sequence Boiler is now in the off cycleGold CGi-4E Gas-Fired Water Boiler Boiler Manual 9b Operation wiring diagrams Wiring diagramOperating instructions Addendum Instruction for Commonwealth of Massachusetts One-half 1/2 inch in size, GAS Vent Directly beCMR 5.082a 1 through CMR 5.082a1 through10a Service and maintenance schedule Verify Proper Operation After Servicing10b Service and maintenance annual start-up 10b Service & maintenance annual start-up Burners and baseCondensate drain system Inducer motorGas piping Cold fill and operating pressuresAir vents and air elimination Limit controls and cutoffsSafety relief valves should be reinspected AT Least Review with ownerBoiler relief valve Shut down boiler11a Troubleshooting general Before troubleshootingAir pressure switch Check the following11b Troubleshooting components Control moduleControl module connections 11c Troubleshooting control module lights Chart 1 Troubleshooting Power light statusChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Does blower motor operate? Item 8 , Verify Sequence of operation, , 12a Replacement parts Section assembly Base Jacket Trim Controls12b Replacement parts section assembly Description Weil-McLain Number Part number12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler 12e Replacement parts trim Part number12f Replacement parts controls Propane gas components13a Dimensions Width13b Ratings DOEBreathing Fresh air Handling ceramic fiber and fiberglass materialsUse Niosh certified dust respirator N95

CGI-4E specifications

The Weil-McLain CGI-4E is a standout in the realm of commercial boilers, designed to meet the rigorous demands of a variety of heating applications. This gas-fired cast iron boiler exemplifies durability, efficiency, and performance, making it a popular choice in various commercial settings, including schools, hospitals, and office buildings.

One of the main features of the CGI-4E is its cast iron construction. Cast iron has long been favored for its excellent heat retention and distribution capabilities, leading to improved overall efficiency. The boiler is designed to maximize heat output while minimizing energy consumption. This characteristic is especially beneficial for businesses seeking to lower their energy costs without sacrificing comfort.

In terms of efficiency, the Weil-McLain CGI-4E boasts an impressive thermal efficiency rating. Its design incorporates advanced technology, allowing it to achieve an AFUE rating of up to 84%. This efficiency is achieved through features such as a full-modulating burner and a unique heat exchanger design that allows for optimal heat transfer and reduced flue gas temperatures.

The CGI-4E is also remarkable for its versatility. It is offered in a variety of sizes, making it suitable for different heating loads. This flexibility allows for installation in a wide range of environments, adapting easily to both existing and new heating systems. Additionally, the boiler comes with multiple venting options, including direct vent and conventional venting, further enhancing its installation flexibility.

Another standout feature is the integrated boiler control system, which simplifies operation and monitoring. This control system optimizes burner performance and enhances safety features, including automatic shut-off in case of system anomalies. The advanced controls also allow for easy integration with building management systems, enabling better energy management and reduced operational costs.

The CGI-4E also emphasizes ease of maintenance, with service-friendly designs that allow technicians to access components without difficulty. This consideration translates to reduced downtime and lower maintenance costs, ensuring that the boiler operates efficiently over its lifetime.

Overall, the Weil-McLain CGI-4E blends reliability, efficiency, and advanced technology, making it a premier choice for commercial heating needs. Its cast iron construction, impressive efficiency ratings, versatile installation options, and user-friendly controls solidify its reputation as a leading boiler solution in the industry.
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